Exploring a manufacturing route to produce WC-based micro-cutting tool with nanostructured material

Micro cutting tools used for micro machining by material removal (e.g. milling, turning) exhibit a high breakage rate due to various physical problems. This is partly due to the material characteristics. The present feasibility study intends to develop and manufacture a microtool by taking advantage of nano-structured powder material, prepared by mechanical milling process, with an ultimate objective to enhance the properties of the developed microtool. Cemented carbide, WC-Co, was used to produce the micro-tool. Hence, a processing route was defined to obtain nano-structured powders ultimately leading to the production of high performance cutting tools by appropriate consolidation. A couple of dies were designed and tested to understand limitations and issues related to the production of such micro tools. The introduction and compaction of the nano-structured WC-Co powder inside the die micro cavity features proved to be a challenge. Following compaction, the micro-tool shaped compacts were sintered at 1400oC for two hours under inert atmosphere. Samples with a large aspect ratio are shown and a couple of challenges are discussed.